EFFICIENCY THROUGH

EXPERTISE & INNOVATION

09.10.2020

Leading partner in the world of metals

FROM IRON ORE TO STEEL PART II

© 2018 2
Overview – From Ore to Steel – Blast Furnace

© 2018 3
 Input and Output

INPUT OUTPUT
Ferrous burden
• Sinter Top Gas
• Basic or Acid Pellets
• Ore Lost burden
Metallic Fe burden • Dust (primary)
• DRI • Sludge (secondary)
• Scrap
Additives
• SiO2 bearer
• CaO bearer
• MgO bearer
Reducing agents
• Coke
Slag
• Nut coke
Injected
Hot Blast
Enrichment O2 HM/Pig Iron
Steam

© 2018 4
The plant units of the blast furnace plant

Hot
Stoves Cyclone Scrubber &
(primary demister
gas (secondary
Charging cleaning) gas cleaning)

Probes
Principle
Stockhouse &
Chemistry
PCI plant

Cast house
© 2018
Training BF Ironmaking 385
The plant units of the blast furnace plant

Hot
Stoves Cyclone Scrubber &
(primary demister
gas (secondary
Charging cleaning) gas cleaning)

Probes
Principle
Stockhouse &
Chemistry
PCI plant

Cast house
© 2018
Training BF Ironmaking 386
Hot-blast stove, apparatus for preheating air blown into a blast furnace, an important step in
raising the efficiency of iron processing. Essentially, the stove is a vertical cylindrical steel shell
lined with firebrick and with the interior separated into two chambers: a combustion chamber, in
which gases from the blast furnace and from other fuel sources such as the coking plant are
burned, and a regenerative chamber filled with a checkerwork of refractory brick heated by the
burned gas. Many blast furnaces are served by three stoves; while two are being heated, the air
blast passes through the regenerative chamber of the third stove on its way to the blast furnace.
Blast furnaces fed with air that has been preheated to temperatures from 900 to 1,250 °C (1,650 to
2,300 °F) can generate smelting temperatures of about 1,650 °C (3,000 °F), significantly reducing
the consumption of coke per ton of iron produced.

© 2018 7
Hot stoves

© 2018 8
Hot stoves: Re-use of top gas energy (MJ)

Coke and fuel 15000

Top Gas 5700 Burden prep. 330

Hot Stoves 2650 Process Steam 100
BLAST
STOVES FURNACE Electricity 60
Hot Blast 2250
Blower 360

1000 kg
Hot Metal

The hot blast stoves accounts for approximately 15% of the total energy input.

© 2018 9
Hot stoves: gas - phase

Checker Chimney
Combustion bricks
chamber

Waste gas

Burner

Air + gas
© 2018 10
Heißwinderzeuger Wind- Phase

Combustion Checker
chamber bricks

1000 to 1300 °C

Hot wind

Hot blast Cold blast from blower

© 2018 11
The plant units of the blast furnace plant

Hot
Stoves Cyclone Scrubber &
Charging (primary demister
gas (secondary
cleaning) gas cleaning)
Probes

Principle
&
Stockhouse
Chemistry
PCI plant

Cast house
© 2018
Training BF Ironmaking 4412
Stock house

Storage, Weighing, Sieving,

Mixing and burden composition
for charges going to the blast
furnace.

© 2018 13
The plant units of the blast furnace plant

Hot
Stoves Cyclone Scrubber &
Charging (primary demister
gas (secondary
cleaning) gas cleaning)
Probes

Principle
&
Stockhouse
Chemistry
PCI plant

Cast house
© 2018
Training BF Ironmaking 4414
 Why pulverized coal injection?

Aim: Reduction of hot metal cost by replacing expensive coke by less

expensive fuel
Example: Coal injection

290 kg coke

1 t hot metal
470 kg Coke

200 kg coal
(~180 kg coke)

© 2018 15
Why pulverized coal injection (PCI)?
Stable (~optimal) fuel consumption for last 25 years
Reduction of fuel rate by fuel injection
The injection of
hydrocarbons through the
tuyere in forms of oil and
gas was first introduced to
reduce the coke combustion
but with oil crisis in 1970s
the PCI injection was
proposed. It was one of the
most major development in
BF technology in the last 20
years.

© 2018 16
Mahl-Trocken-Anlage und Kohleeinblasung

Grinding and Drying Plant Injection Plant

FILLING
BAGFILTER
RAW COAL
STACK MAIN BAG-FILTER FILLING
BAGFILTER
RAW COAL
DEPRESSURIZING DEPRESSURIZING
STORAGE BIN BAGFILTER BAGFILTER

DRYING GAS MAIN FAN

PULVERIZED COAL
RV RV ROTARY VALVES STORAGE BIN

SCREW CONVEYOR
DILUTION AIR FAN

COMBUSTION AIR SCREENING MACHINES

FAN

NATURAL GAS

BLAST FURNACE GAS COARSE

VERTICAL
MATERIAL
ROLLER
HOT GAS GENERATOR BINS
MILL
CONVEYING
HOPPERS
PULVERIZED
CONVEYING COAL TUYERES
LINE FS

FS
STATIC
DISTRIBUTOR
PRESSURIZING INJECTION
GAS VESSEL LINES

5718715-0387254

© 2018 17
The plant units of the blast furnace plant

Hot
Stoves Cyclone Scrubber &
Charging (primary demister
gas (secondary
cleaning) gas cleaning)
Probes

Principle
&
Stockhouse
Chemistry
PCI plant

Cast house
© 2018
Training BF Ironmaking 4418
The Bell Top system

In former times, the blast furnace

was charged by bells. The air
tightness is performed by two bells.
The upper bell opens while the lower
one is closed. The upper bell closes
and then the lower bell opens.
Burden distribution control is very
limited (1 single geometry, only
variation of opening speed is
possible) and the counter pressure
of the furnace must be quite low.

Top gas pressure and its effect on

the productivity and the control of
burden distribution.
Double bed type was invented to
have this property.

© 2018 19
The Bell Top system

© 2018 20
Evolution of the Bell Top system

No much control on
the blast furnace
charging and
consequently no
control on the gas
distribution

© 2018 21
The Bell Less Top – A Revolution!

© 2018 22
The Bell Less Top – A Revolution!

Some of the advantages:

1. Increased productivity,
decreased coke consumption
2. Reduced refectory erosion
3. Improve the gas utilization
4. Lower silicon content in the
hot metal
5. …

© 2018 23
 Charging Sequence of a 2H BLT

Distribution NO Material Flow NO Material Flow

Rocker ALL Flaps closed ALL Flaps closed
USV closed USV closed
USV open USV open

Hopper 1

BF p. Atm. p. Relief Equalizing Atm. p. BF p. Equalizing Relief

Hopper 2

LMG & LMG & LMG &

LMG &
LSV open LSV closed LSV open Rotating
LSV closed
Chute
CTG

1 2 3 4
© 2018
Training BF Ironmaking - PBM 2424
The plant units of the blast furnace plant

Hot
Stoves Cyclone Scrubber &
Charging (primary demister
gas (secondary
cleaning) gas cleaning)
Probes
Principle
&
Stockhouse Chemistry

PCI plant

Cast house
© 2018
Training BF Ironmaking 4425
Introduction - The BF Zones

Stock Line
BF Zones:
Throat
Burden layers

Coke layers Shaft

Cohesive zone

Coke slits / windows

Dripping zone Belly

Active coke zone Bosh

Dead-man
Raceway
Slag Hearth
Iron
© 2018 26
Raceway

Hot blast

Oxygen

Oxygen N2
addition
CO

Coke
Heat
Carbon

PCI Slag
H2

Steam
H2O
Humidit.

© 2018 27
Raceway

Hot blast

Oxygen

Oxygen
addition CO

PCI H2
volatiles
CnHx
Natural gas
/oil

© 2018 28
 Off gas Ferrous burden & Coke
The Blast Furnace
=
Counter-current Reactor
Hot blast Pig iron & Slag

© 2018 29
Energy aspect of the furnace Gas
CaCO3  CaO  CO2
Drying, Dehydration, MgCO3  MgO  CO2

& Decarbonisation FeCO3  FeO  CO2

FeOH 2  FeO  H 2O
Solid
3Fe2O3  CO / H 2  2 Fe3O4  CO2 / H 2O
Indirect reduction
Fe3O4  CO / H 2  3FeO  CO2 / H 2O

Chemical reserve zone

Thermal reserve zone

Magnetite & Wustite

CO2
Equilibrium FeO1.056 ;  0.3
CO2  CO

FeO  C  Fe  CO
Direct reduction FeO  H 2  Fe  H 2O

Csolid  Cliquid
SiO2  2C  Si  2CO
Solid / Liquid
P2O5  5C  P  5CO2
interaction
MnO  C  Mn  CO
FeS  CaO  C  Fe  CaS  CO

50°C 200°C 600°C 1000°C 1400°C 1800°C 2200°C

© 2018 30
© 2018 31
 Introduction - The BF Temperature Zones

BF Temperature Zones:

Top gas (100 °C)

H2O Evaporation
(100 °C)
Start of reduction reactions
(500 °C)
Temperature reserve
zone (900 °C)
Start of softening front
Cohesive (1000 – 1200 °C)
zone Hot blast
Iron and slag melt (1150
– 1400 °C) (1000 – 1250 °C)

Raceway Flame
(2000 – 2300 °C)
HM Temperature (1500 °C)
Dead-man (packed coke
bed)
© 2018 32
What control parameters are available?

Burden Materials ?
 Change raw materials
The efficiency of the
 Increase quality
blast furnace process
is mainly conditioned by the gas
Hot Blast ? distribution
 Temperature
 Enrichment
 Humidity
The gas distribution is controlled by the
Burden distribution
burden? distribution
 Coke layer height
 Local coke/ore Ratio
 Charging sequence

© 2018 33
The plant units of the blast furnace plant

Hot
Stoves Cyclone Scrubber &
Charging (primary demister
gas (secondary
cleaning) gas cleaning)
Probes

Principle
&
Stockhouse
Chemistry
PCI plant

Cast house
© 2018
Training BF Ironmaking 4434
Sonden
Radar
• Burden level and descent speed
Fixed above burden probes
• Gas composition
• Temperature- und gas distribution
Movable above burden probes
• Gas composition
All probe info related to gas distribution
• Temperature- und gas distribution
• Burden profile
Direct or indirect via burden
Movable in burden probes
• Temperature- und gas distribution
distribution
• Burden profile
Pressure measurements at the wall
• Gas permeability
Charging model
• Visualization of theoretical material
distribution
© 2018 35
Fixed Above Burden Gas & Temperature Probe

© 2018 36
In-Burden Probe

© 2018 37
The plant units of the blast furnace plant

Hot
Stoves Cyclone Scrubber &
Charging (primary demister
gas (secondary
cleaning) gas cleaning)
Probes

Principle
&
Stockhouse
Chemistry
PCI plant

Cast house
© 2018
Training BF Ironmaking 4438
Blast furnace hearth

Dead Man Coke with about 25-

30% void space for liquid iron
Gas
and slag Raceway
•The hearth is a refractory vessel
contained by the steel blast furnace Tuyere
shell.
•Cooling of the steel shell is
essential to avoid overheating of the Dripping liquids
refractory and shell to the point of
failure. Taphole
•The taphole or tapholes are
positioned such that a pool, or
sump, of liquids remains in the
bottom of the hearth to protect the Mushroom
pad, even after casting. Slag
•The lower part, known as the
salamander, is only tapped at the
Hot metal
end of a campaign.
© 2018 39
Blast furnace hearth

The operation of a blast furnace is a continuous process

and the furnace continues to produce liquid iron and slag
as long as it is in operation.
On the other hand evacuating the liquids through the tap
hole is a discontinuous process as the tap hole has to be
“renewed” after each tap because of the high wear from
the liquids passing through it.
Iron and slag can accumulates in the hearth, but because
there is a limit to the amount that can be tolerated
before it interferes with furnace operation, the iron and
slag must be removed from the furnace through the
taphole according to a strict schedule.

© 2018 40
Main runner

© 2018 41
Type of Runners

Main trough
Slag runner
Skimmer
Cast iron runner
Drain runner
Tilting runner

© 2018 42
Cast floor equipment

Claygun

Runner Drilling machine

Cover manipulator

Figure: Flat cast house design Stahlwerke Bremen BF 2

© 2018 43
The plant units of the blast furnace plant

Hot
Stoves Cyclone Scrubber &
Charging (primary demister
gas (secondary
cleaning) gas cleaning)
Probes

Principle
&
Stockhouse
Chemistry
PCI plant

Cast house
© 2018
Training BF Ironmaking 4444
Gas Cleaning System Elements

Dry Gas Cleaning Unit

• Dedusting with high dust separation efficiency
(use of dust in sinter plant)
• Low Zn and Pb contents in the dust to avoid an
accumulation in the furnace Cyclone
(dry gas
cleaning)
Wet Gas Cleaning Unit
• Blast furnace top pressure control
• Cooling of the BF top gas Scrubber (wet
gas cleaning)

• Obtain gas dust content of less than 5 mg/Nm3

Demister
Demister
• Reducing the water droplet content

© 2018 45
Overview – From Ore to Steel – Oxygen Converter

© 2018 46
 Transport of liquid pig iron

Tapping

Transport
Torpedo  Ladle
© 2018 47
Converter

•Transform Hot Metal into Steel

• Removal of Si and C

© 2018 48
Converter

From hot metal comes crude steel. The impurities are oxidized in
converters by top-blowing oxygen through a water-cooled lance.
Certain quantities of scrap, accounting for as much as 25% of the
total charge, are added as cooling agents, since the oxidation
process generates a strong amount of heat.

© 2018 49
BOF Bath analysis and blowing time

4.0 0.08 1600

3.0 0.06 1550

Temperature [°C]
C, P, Mn, Si [%]

S [%]
2.0 0.04 1500

1.0 0.02 1450

0.0 0.00 1400

0 5 10 15 20
Blowing time [min]
© 2018 50
Video – steel shop

© 2018 54
Overview – From Ore to Steel – Ladle Treatment

© 2018 55
Secondary Metallurgy

• Removal of H2 and N2
• Removal of carbon, oxides and sulfides
• Control of inclusions
• Temperature adjustment and homogenisation
• Chemical adjustment and homogenisation

The RH vacuum circulation process

© 2018 56
Overview – From Ore to Steel – Continuous Casting

© 2018 57
Continuous casting
Ladle-Tourret
Pre-heating station

Ladle

Tundish

Starter chain

Vibro- Support rolls and

Mold secondary cooling

Strand

© 2018 58
Continuous casting

© 2018
Training BF Ironmaking 9060
Overview – From Ore to Steel – Hot Strip Mill

© 2018 61
Hot Strip Mill sceme

Reheating furnaces

Coil finishing
Waste gas
heat recovery

Preparation

Milling

Downcoilers
© 2018 62
Hot strip mill

Semi-Finished Shape

© 2018 63
Video – Hot rolling mill

© 2018 64
A different view of a steel-making plant

Thanks for your attention!

Please feel free to ask questions

© 2018 65
 LEADING PARTNER
IN THE WORLD OF METALS

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